Drop analysis system

Abstract

A drop analysis/drop check system allows a plurality of printheads to remain stationary during analysis to emulate operation of an actual piezoelectric microdeposition system. The system provides accurate tuning of individual nozzle ejectors and allows for substrate loading and alignment in parallel with drop analysis/drop check. The drop analysis/drop check system includes a motion controller directing movement of a stage, a printhead controller controlling a printhead to selectively eject drops of fluid material to be deposited on a substrate, and a camera supported by the stage for movement relative to the printheads. The camera receives a signal from the motion controller to initiate exposure of the camera and captures an image of the drops of fluid material ejected by the printheads. A light-emitting device includes a strobe controller that receives a signal from the camera to supply light to an area including the liquid drops during camera exposure.

1. An analysis system comprising:
 a stage; 
 a motion controller that directs movement of the stage; 
 a printhead; 
 a printhead controller that is in communication with the motion controller, that controls the printhead to selectively eject drops of fluid material to be deposited on a substrate, and that controls the printhead to selectively eject drops of fluid material for drop analysis; 
 a camera supported by the stage for movement relative to the printhead, the camera selectively receiving a first trigger signal from the motion controller to initiate exposure of the camera and capturing of an image of the drops of fluid material ejected by the printhead; 
 a light-emitting device having a strobe controller, the strobe controller selectively receiving a second trigger signal from the camera to supply a pulse of light from the light-emitting device to an area including the drops during the exposure; 
 a prism supported by the stage for movement relative to the printhead, wherein the pulse of light from the light-emitting device is folded by the prism to pass through the area and arrive at the camera; 
 a diffuser located proximate to the light-emitting device; 
 a condensing lens located between the diffuser and the prism; 
 an imaging lens located proximate to the camera; 
 a first mirror located between the prism and the imaging lens; and 
 a second mirror located between the first mirror and the imaging lens, 
 wherein the motion controller positions the stage such that the area is located between the first mirror and the prism. 
 
     
     
       2. The analysis system of  claim 1  further comprising a computer in communication with the camera, wherein the computer is located remotely from the camera. 
     
     
       3. The analysis system of  claim 1  further comprising a computer in communication with the camera, wherein the camera transmits image data to the computer following the exposure, and wherein the computer includes a processor and memory storing predetermined operating parameters of the printhead for comparison to data received from the camera. 
     
     
       4. The analysis system of  claim 1  wherein the printhead controller selectively receives instructions from the motion controller to deposit the drops of fluid material on the substrate, and wherein the strobe controller is in communication with the printhead controller and the camera. 
     
     
       5. The analysis system of  claim 1  wherein the printhead is stationary during the exposure of the camera and illumination of the light-emitting device. 
     
     
       6. The analysis system of  claim 1  further comprising a substrate stage that supports the substrate and that moves the substrate in a direction perpendicular to a direction of travel of the printhead. 
     
     
       7. The analysis system of  claim 1  wherein the camera captures a predetermined number of images of the drops of fluid material and the predetermined number of images is based on a volume of the drops of fluid material. 
     
     
       8. The analysis system of  claim 1  wherein the drops of fluid material are ejected generally in a Z direction, and wherein the stage moves the camera along a Z axis parallel to the Z direction. 
     
     
       9. The analysis system of  claim 8  wherein the stage positions the camera along the Z axis to capture the image of the drops of fluid material at a distance from a nozzle of the printhead that represents an effective contact distance during printing on the substrate. 
     
     
       10. The analysis system of  claim 1  wherein the prism includes a reduced top portion. 
     
     
       11. The analysis system of  claim 6  wherein the substrate stage is configured to receive the substrate in parallel with exposure of the camera and illumination of the light-emitting device. 
     
     
       12. The analysis system of  claim 6  wherein the stage is configured to move along X, Y, and Z axes, wherein the X, Y, and Z axes are perpendicular to each other.